Expedition 2003 Grand Vitara

[josh_GV]

I bought a 2003 Suzuki Grand Vitara with 68,000 miles.

This vehicle will be used for going down dirt roads, climbing hills to paragliding launches, and attaching a roof top tent for camping excursions.

This thread will detail modifications to the vehicle to support my camping and paragliding adventures.

I’ve owned 2dr TJ, 4dr JK, and SX4s …. The jeeps were too heavy and the lifted SX4 did not have 4lo… The Grand Vitara platform was the lightest true 4x4 I could find and still be lite and nimble!

It’s time to start modifications!



Vehicle General Specs: 2.5l V6 engine, Weight: 3100lbs, Steel Front Axle Housing! Automatic 4x4 (4HI&4LO), 225/60R16, Cruise Control, and AC.

 

[josh_GV]

DAY 1: NEW TIRES - After completing some regular maintenance items, this an awesome low mileage Vitara was super clean and ready for it first modification!

Since I was planning on lifting an inch or two soon and the tires were worn out, I decided to get a set of Dextero All Terrains 235/70r16.

Stock size: 225/60R16 (26.6in)
New size: 235/70R16 (29in)

After install there was no rubbing on the front and they are smooth and quiet.



There is one spot on the back that had slight rubbing, but only at full stuff.

 

[josh_GV]

Day 2: Well it’s time to install the lift. I got a 2in spacer lift installed over the weekend, did the passenger support shaft bushing while I was in there. I chose this lift because anything taller would start effecting driveshaft angles. I also modified a set of KYB 343149 rear shocks and installed camber bolts. I noticed that the camber bolts should be adjusted all the way out and that sets your camber back to stock.

Upgrades list:
- 2” spacer lift with strut and sway bar spacers
- Rear shocks: KYB 343149 (modified bolt sleeve)
- Camber bolts: SPC 81250
- CV differential support bushing SZT-001 OEM 2761965D00







Got a quick alert alignment done. I like the way it turned out.



Alignment specs to follow for these vitaras;


Now, with the lift, the tire doesn’t rub in the back.



A couple flex shots.

 

[josh_GV]

Day 3: After driving around for a few months with the spacer lift, I noticed the polyurethane spacers starting to crush. I always wanted a suspension that was 2in lift that was only springs (and no spacers) so I started looking into it and here’s what I ended up with.

Upgrades include:
- Front: Springs from 2002 Jeep Liberty Sport front struts.
- Rear: Springs from the rear of a 2002 Focus Wagon.

THE REAR: The rear springs I used are CC881 from a 2002 Ford Focus Wagon. Since I only wanted a 2 inch lift, I cut off one coil on each spring.



You will need a solution to keep the top of the rear spring centered on the coil perch as the ID of the coil is larger than stock tangential end. I used a rubber 1/8” mat (2inches wide) and wrapped it around the upper posts until it was the right diameter and secured it with silicone.



Then using Ford Focus spring pad on the top, I installed the springs and had 2.5” of lift.
These springs are softer than stock at 166ppi.



THE FRONT: The front springs are from a 2002 Jeep Liberty Sport. After cutting 1/2 coil on drivers side and 1/4 coil on passenger side. I ended up with 1.75” lift in the front (which was the same as my spacer lift). The springs are 386 ppi, 3.22” ID. This makes them slightly softer than the stock springs. This spring diameter ended up being the largest spring coil that can fit into the upper cup. The springs were the hardest springs I’ve ever installed out of (all the lift kits I’ve ever done) due the limited clearances and the spring clamps.



The end result was a junk yard lift that works great! I’ve already been off-road to test out the softer springs and love the way that the handling feels. These little Vitaras perform like they have SXS in their blood.

 

[operator john]

Cool build . These Vitaras are tuff little rigs ,body on frame ! & simple to work on & mod. Plus a small foot print.

 

[josh_GV]

DAY 4: adding Manual Hubs and 1in Wheel Spacers. I decided to add Manual hubs from a Gen 1 Geo Tracker. This allows me to unlock the CV shafts from the Wheel, and perhaps gain a little more fuel efficiency. I still have the vacuum actuator working for my automatic 4x4 engagement, so this will work in tandem with that system.

Clean and Paint: I first had to clean, rebuild and paint the manual hubs.


HUBS INSTALLED: installed and everything turns nice and easy. These sure do stick out far!



ADDED WHEEL SPACERS: added a 1in wheel spacer on all 4 wheels. It brought the wheel out to be inline with the front of the hub.


FINAL RESULT: with the modified trim ring and 1in wheel spacer, I was able to get a flush OEM look.

 

[Christian P.]

Great sensitive choice.

 

[Wyo37]

Very cool build